U.S. patent application number 11/736369 was filed with the patent office on 2007-11-08 for dual clutch hybrid powershift transmission.
This patent application is currently assigned to MAGNA POWERTRAIN USA, INC.. Invention is credited to John R. Forsyth.
Application Number | 20070259748 11/736369 |
Document ID | / |
Family ID | 38661834 |
Filed Date | 2007-11-08 |
United States Patent
Application |
20070259748 |
Kind Code |
A1 |
Forsyth; John R. |
November 8, 2007 |
Dual Clutch Hybrid Powershift Transmission
Abstract
A dual-clutch transmission for use in a motor vehicle having an
engine and a driveline includes an output shaft adapted for
connection to the driveline and a planetary gearset in constant
driving engagement with the output shaft. An input shaft is driven
by the engine. A first constant mesh gearset is in selective
driving communication with a first member of the planetary gearset.
A second constant mesh gearset is in selective driving
communication with a second member of the planetary gearset. A
first clutch is operable for establishing a releasable drive
connection between the input shaft and the first constant mesh
gearset. A second clutch is operable for establishing a releasable
drive connection between the input shaft and the second constant
mesh gearset. A motor is selectively drivingly coupled to a third
member of the planetary gearset.
Inventors: |
Forsyth; John R.;
(Washington, MI) |
Correspondence
Address: |
HARNESS, DICKEY & PIERCE, P.L.C.
P.O. BOX 828
BLOOMFIELD HILLS
MI
48303
US
|
Assignee: |
MAGNA POWERTRAIN USA, INC.
Troy
MI
|
Family ID: |
38661834 |
Appl. No.: |
11/736369 |
Filed: |
April 17, 2007 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60746513 |
May 5, 2006 |
|
|
|
Current U.S.
Class: |
475/5 |
Current CPC
Class: |
Y10T 74/19233 20150115;
F16H 3/725 20130101; Y02T 10/62 20130101; Y10S 903/91 20130101;
B60Y 2400/428 20130101; F16H 3/006 20130101; Y02T 10/6221 20130101;
B60K 6/547 20130101; B60K 6/40 20130101; F16H 2200/0052 20130101;
B60K 6/48 20130101; Y10S 903/919 20130101; Y10T 74/19228 20150115;
F16H 37/042 20130101 |
Class at
Publication: |
475/5 |
International
Class: |
F16H 3/72 20060101
F16H003/72 |
Claims
1. A dual-clutch transmission for use in a motor vehicle having an
engine and a driveline, comprising: an input shaft driven by the
engine; an output shaft adapted for connection to the driveline; a
planetary gearset in constant driving engagement with said output
shaft; a first constant mesh gearset selectably connectable with a
first member of said planetary gearset; a second constant mesh
gearset selectably connectable with a second member of said
planetary gearset; a first clutch operable for establishing a
releasable drive connection between said input shaft and said first
constant mesh gearset; a second clutch operable for establishing a
releasable drive connection between said input shaft and said
second constant mesh gearset; and an electric motor selectively
drivingly coupled to a third member of said planetary gearset.
2. The dual-clutch transmission of claim 1 wherein said planetary
gearset is a compound planetary gearset, and wherein said output
shaft is fixed to a fourth member of said compound planetary
gearset.
3. The dual-clutch transmission of claim 2 wherein a first forward
drive ratio is provided when a first torque path through said first
clutch is established, wherein a second forward drive ratio is
provided when a second torque path through said second clutch is
established, and wherein a third forward drive ratio is provided
when both the first and second torque paths are established.
4. The dual-clutch transmission of claim 1 further including a
third constant mesh gearset driven by said input shaft and a
gearset clutch operable to releasably couple said third constant
mesh gearset to said third member of said planetary gearset.
5. The dual-clutch transmission of claim 1 further including a
first device operable to restrict rotation of said first member of
said planetary gearset.
6. The dual-clutch transmission of claim 1 wherein a gear
associated with said first constant mesh gearset is rotatably
supported on a first countershaft that surrounds a portion of said
output shaft.
7. A dual-clutch transmission for use in a motor vehicle having an
engine and a driveline comprising: an input shaft driven by the
engine; an output shaft adapted for connection to the driveline; a
planetary gearset in constant driving engagement with said output
shaft; a first countershaft fixed to a first member of said
planetary gearset; a second countershaft fixed to a second member
of said planetary gearset; a first engine clutch operable for
establishing a releasable drive connection between said input shaft
and a first transfer shaft; a second engine clutch operable for
establishing a releasable drive connection between said input shaft
and a second transfer shaft; a first constant mesh gearset driven
by said first transfer shaft; a second constant mesh gearset driven
by said second transfer shaft; first and second shift clutches,
said first shift clutch operable to releasably drivingly couple
said first gearset to said first countershaft, and said second
shift clutch operable to releasably drivingly couple said second
gearset to said second countershaft; and a motor selectively
drivingly coupled to a third member of said planetary gearset.
8. The dual-clutch transmission of claim 7 further comprising a
third constant mesh gearset driven by said second transfer shaft
and a fourth constant mesh gearset driven by said first transfer
shaft.
9. The dual-clutch transmission of claim 8 wherein said first shift
clutch is operable to releasably couple said fourth gearset and
said first countershaft, and wherein said second shift clutch is
operable to releasably couple said third gearset and said second
countershaft.
10. The dual-clutch transmission of claim 9 further including a
fifth shift driven by said second transfer shaft.
11. The dual-clutch transmission of claim 10 further including a
third shift clutch operable to releasably couple said fifth gearset
to said second countershaft.
12. The dual-clutch transmission of claim 7 further including a
controller for controlling actuation of said first and second
engine clutches.
13. The dual-clutch transmission of claim 12 further including
first and second actuators controlling said first and second engine
clutches, respectively, said controller controlling actuation of
said first and second actuators.
14. The dual-clutch transmission of claim 13 wherein said first and
second shift clutches are electrically-actuated synchronizer
clutches.
15. The dual-clutch transmission of claim 7 wherein said first
transfer shaft surrounds a portion of said input shaft.
16. The dual-clutch transmission of claim 15 wherein said second
transfer shaft surrounds another portion of said input shaft.
17. The dual-clutch transmission of claim 7 wherein said first and
second constant mesh gearsets are axially positioned between said
first engine clutch and said second engine clutch.
18. The dual-clutch transmission of claim 7 wherein said first and
second engine clutches are normally closed clutches operable to
transmit torque without an application of external force.
19. The dual-clutch transmission of claim 7 further including a
third constant mesh gearset driven by said input shaft and a third
shift clutch operable to releasably couple said third constant mesh
gearset to said third member of said planetary gearset.
20. The dual-clutch transmission of claim 7 wherein said planetary
gearset is a ravigneaux-type gearset.
21. The dual-clutch transmission of claim 20 wherein said output
shaft is fixed to a fourth member of said planetary gearset.
22. The dual-clutch transmission of claim 7 further including a
first device operable to restrict rotation of said first member of
said planetary gearset.
23. The dual-clutch transmission of claim 22 further including a
second device operable to restrict rotation of said second member
of said planetary gearset.
24. A dual-clutch transmission for use in a motor vehicle having an
engine and a driveline comprising: an input shaft being driven by
the engine; an output shaft adapted for connection to the
driveline; a planetary gearset in constant driving engagement with
said output shaft; a first clutch operable for establishing a
releasable drive connection between said input shaft and a first
transfer shaft; a second clutch operable for establishing a
releasable drive connection between said input shaft and a second
transfer shaft; a first constant mesh gearset driven by said first
transfer shaft; a second constant mesh gearset driven by said
second transfer shaft; first and second gearset clutches, said
first gearset clutch operable to releasably drivingly couple said
first gearset to a first member of said planetary gearset, said
second gearset clutch operable to releasably drivingly couple said
second gearset to a second member of said planetary gearset; and a
motor selectively drivingly coupled to a third member of said
planetary gearset.
25. The dual-clutch transmission of claim 24 wherein said planetary
gearset is a compound planetary gearset, said output shaft is fixed
to a fourth member of said compound planetary gearset.
26. The dual-clutch transmission of claim 25 further including a
third constant mesh gearset driven by said input shaft and a third
gearset clutch operable to releasably drivingly couple said third
constant mesh gearset to said third member of said planetary
gearset.
27. The dual-clutch transmission of claim 26 wherein said third
gearset clutch is operable to selectively drivingly couple said
motor to said third member of said planetary gearset.
28. The dual-clutch transmission of claim 24 wherein a first
forward drive ratio is established when a first torque path
including said first clutch is completed, a second forward drive
ratio is established when a second torque path including said
second clutch is completed, and a third forward drive ratio is
established when both said first and second torque paths are
completed.
29. The dual-clutch transmission of claim 28 wherein during
operation in said first forward drive ratio said second member of
said planetary gearset is restricted from rotation.
30. The dual-clutch transmission of claim 29 wherein during
operation in said the second forward drive ratio said first member
of said planetary gearset is restricted from rotation.
31. The dual-clutch transmission of claim 30 wherein during
operation in said third forward drive ratio both of said first and
second members of said planetary gearset are free to rotate.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/746,513, filed on May 5, 2006. The disclosure of
the above application is incorporated herein by reference.
BACKGROUND
[0002] The present disclosure relates to transmissions for use in
motor vehicles and, more particularly, to a dual-clutch automated
hybrid transmission applicable for use in such motor vehicles.
[0003] Automobile manufacturers continuously strive to improve fuel
efficiency. Efforts to improve fuel efficiency, however, are
typically offset by the need to provide enhanced comfort and
convenience to the vehicle operator. For example, it is well known
that manual transmissions are more fuel efficient than automatic
transmissions, yet a majority of all passenger vehicles are
equipped with automatic transmissions due to the increased
convenience they provide.
[0004] More recently, "automated" variants of conventional manual
transmissions have been developed which shift automatically without
any input from the vehicle operator. Such automated transmissions
typically include a plurality of power-operated actuators that are
controlled by a transmission controller to shift traditional
synchronized dog clutches. However, such automated transmissions
have the disadvantage that there is a power interruption in the
drive connection between the input shaft and the output shaft
during sequential gear shifting. Power interrupted shifting may
result in a harsh shift feel which is generally considered to be
unacceptable when compared to the smooth shift feel associated with
most automatic transmissions. To overcome this problem, automated
twin-clutch transmissions have been developed which can be
powershifted to permit gearshifts to be made under load. Examples
of such automated manual transmissions are shown in U.S. Pat. Nos.
5,966,989 and 5,890,392. While such powershift twin-clutch
transmissions overcome several drawbacks associated with
conventional single-clutch automated transmissions, a need exists
to develop simpler and more robust transmissions which advance the
automotive transmission technology.
[0005] Automobile manufacturers are also actively working to
develop alternative powertrain systems in an effort to reduce the
level of pollutants exhausted into the air by conventional
powertrains equipped with internal combustion engines. Significant
development has been directed to electric vehicles and fuel cell
vehicles. Unfortunately, these alternative powertrain systems
suffer from several disadvantages and, for all practical purposes,
are still under development. However, several different hybrid
electric vehicles are equipped with an internal combustion engine
and an electric motor that can be operated independently or in
combination to drive the vehicle.
[0006] There are two types of hybrid vehicles, namely series hybrid
and parallel hybrid. In a series hybrid vehicle, power is delivered
to the wheels by the electric motor which draws electrical energy
from the battery. The engine is used in series hybrid vehicles to
drive a generator which supplies power directly to the electric
motor or charges the battery when the state of charge falls below a
predetermined value. In parallel hybrid vehicles, the electric
motor and the engine can be operated independently or in
combination pursuant to the running conditions of the vehicle.
Typically, the control strategy for such parallel hybrid vehicles
utilizes a low-load mode where only the engine is used to drive the
vehicle, and an intermediate assist mode where the engine and
electric motor are both used to drive the vehicle. Regardless of
the type of hybrid drive system used, hybrid vehicles are highly
modified versions of conventional vehicles that are expensive due
to the componentry, required control systems, and specialized
packaging requirements.
SUMMARY
[0007] Accordingly, it may be advantageous to position the clutches
of a dual-clutch transmission at opposite ends of the transmission
to provide maximized cooling. Additionally, by positioning the
clutches in this manner, each clutch assembly may be appropriately
sized without the requirement that the shift clutch be packaged
within the start clutch. Furthermore, depending on the location of
the output shaft of the transmission, it may be possible to provide
drive torque to front and rear propeller shafts without the use of
a separate transfer case.
[0008] Additionally, the present disclosure provides a dual-clutch
transmission and a control system for permitting automatic shifting
of the dual-clutch transmission.
[0009] Furthermore, the dual-clutch automated transmission
disclosed herein may be used as a hybrid drive system in
conjunction with the internal combustion engine.
[0010] In one configuration, a dual-clutch transmission is
described for use in a motor vehicle having an engine and a
driveline. The transmission includes an output shaft adapted for
connection to the driveline and a planetary gearset in constant
driving engagement with the output shaft. An input shaft is driven
by the engine. A first constant mesh gearset is in selective
driving communication with a first member of the planetary gearset.
A second constant mesh gearset is in selective driving
communication with a second member of the planetary gearset. A
first clutch is operable for establishing a releasable drive
connection between the input shaft and the first constant mesh
gearset. A second clutch is operable for establishing a releasable
drive connection between the input shaft and the second constant
mesh gearset. A motor is selectively drivingly coupled to a third
member of the planetary gearset.
[0011] Further areas of applicability will become apparent from the
description provided herein. It should be understood that the
description and specific examples are intended for purposes of
illustration only and are not intended to limit the scope of the
present disclosure.
DRAWINGS
[0012] The drawings described herein are for illustration purposes
only and are not intended to limit the scope of the present
disclosure in any way.
[0013] FIG. 1 is a schematic view of a dual-clutch automated
transmission as described in the disclosure;
[0014] FIG. 2 is a lever diagram indicating the interconnection of
various components of the dual-clutch automated transmission shown
in FIG. 1; and
[0015] FIG. 3 is a diagrammatic illustration of the transmission
control system adapted for use with the dual-clutch automated
transmission shown in FIG. 1.
DETAILED DESCRIPTION
[0016] The following description is merely exemplary in nature and
is not intended to limit the present disclosure, application, or
uses. It should be understood that throughout the drawings,
corresponding reference numerals indicate like or corresponding
parts and features.
[0017] With reference to FIGS. 1-3 of the accompanying drawings, a
dual-clutch automated transmission, hereinafter referred to as
transmission 10, will now be described. Transmission 10 is driven
by the output of an engine 12 and generally includes a first clutch
14, a second clutch 16, an input shaft 20, a first tubular transfer
shaft 22, a plurality of output gearsets 24, a first countershaft
26, a second tubular transfer shaft 28, a second countershaft 30, a
third countershaft 32, a planetary gearset 33, an output shaft 34,
and a shift control system 35.
[0018] First clutch 14 is a multi-plate clutch having a plurality
of inner clutch plates 36 in splined engagement with first tubular
shaft 22. A plurality of outer clutch plates 38 are in splined
engagement with a housing 40 fixed to input shaft 20. First clutch
14 is normally operable in an engaged or closed state to establish
a drive connection between input shaft 20 and first transfer shaft
22. A first actuator 42 is provided to apply a force to cause inner
clutch plates 36 and outer clutch plates 38 to separate from one
another and cease the transfer of torque through first clutch 14.
In the embodiment shown, first actuator 42 may be a
hydraulically-actuated device that controls the magnitude of torque
transferred through first clutch 14. First actuator 42 may also
fully release first clutch 14 so no torque is transferred
therethrough.
[0019] Second clutch 16 includes a plurality of inner clutch plates
50 in splined engagement with second transfer shaft 28 and a
plurality of outer clutch plates 52 in splined engagement with a
housing 54. Housing 54 is fixed to input shaft 20 at an end
opposite first clutch 14. Second clutch 16 is also a normally
closed clutch that transmits torque when not acted upon by an
external force. In the closed condition, inner clutch plates 50
frictionally engage outer clutch plates 52 and torque is
transferred between engine output 12 and second transfer shaft 28.
Inner clutch plates 50 and outer clutch plates 52 are axially
moveable to positions spaced apart from one another where second
clutch 16 does not transfer torque. A second actuator 60 is
operable to control second clutch 16 to selectively transfer a
predetermined quantity of torque between input shaft 20 and second
transfer shaft 28 or fully release the clutch plates from one
another. While it is contemplated that first actuator 42 and second
actuator 60 are hydraulically operated devices, other types of
actuators including electrically-powered actuators are within the
scope of the present disclosure.
[0020] The plurality of output gearsets 24 include a first and
third gearset 70 having a first and third drive gear 72 fixed to
first transfer shaft 22 which is meshed with a first and third
speed gear 74 rotatably supported on first countershaft 26. A
second gearset 76 includes a second drive gear 78 fixed to second
transfer shaft 28 which is in meshed engagement with a second speed
gear 80 rotatably supported on second countershaft 30. A fourth
gearset 88 includes a fourth drive gear 90 fixed to second transfer
shaft 28 which is in meshed engagement with a fourth speed gear 92
rotatably supported on second countershaft 30. A fifth gearset 94
includes a fifth drive gear 96 fixed to first transfer shaft 22
which is in meshed engagement with a fifth speed gear 98 rotatably
supported on first countershaft 26. A sixth gearset 100 includes a
sixth drive gear 102 fixed to second transfer shaft 28 which is in
meshed engagement with a sixth speed gear 104 rotatably supported
on second countershaft 30. A headset 114 includes a headset drive
gear 116 fixed to input shaft 20 which is in meshed engagement with
a headset speed gear 118 rotatably supported on third countershaft
32.
[0021] Planetary gearset 33 is depicted as a ravigneaux-type
gearset having a first sun gear 120 fixed to third countershaft 32
and meshed with a first set of pinion gears 122 rotatably supported
on a carrier 124. Carrier 124 is fixed to second countershaft 30. A
second set of pinion gears 126 are also rotatably supported on
carrier 124. A second sun gear 127 is fixed to first countershaft
26 and meshed with second set of pinion gears 126. A ring gear 128
is fixed to output shaft 34 and is in meshed engagement with first
set of pinion gears 122. First set of pinion gears 122 are also
meshed with second set of pinion gears 126.
[0022] To provide a robust, compact package, input shaft 20 is
concentrically supported in the front bearing bulkhead portion of a
housing 152 by a bearing assembly 150 (FIG. 1). Housing 152 also
includes a center web 154 rotatably supporting a middle portion of
input shaft 20 with a bearing assembly 156. An opposite end of
input shaft 20 is rotatably supported in housing 152 by another
bearing assembly 158. Second transfer shaft 28 concentrically
surrounds a portion of input shaft 20 and is rotatably supported
thereon. First transfer shaft 22 also concentrically surrounds a
portion of input shaft 20 and is rotatably supported thereon.
Second countershaft 30 concentrically surrounds output shaft 34 and
is supported by bearing assemblies 160 and 162. First countershaft
26 also concentrically surrounds a portion of second countershaft
30 and is rotatably supported by bearing assemblies 164 and
166.
[0023] Output shaft 34 is drawn to include a first (left) end
portion extending from housing 152 and a second (right) end portion
also extending from housing 152. This graphical depiction indicates
that output shaft 34 may have either of its ends connected to
driveline components or even possibly both ends connected to
various driveline components. If the first end portion of output
shaft 34 is used as a drive connection, it is contemplated that
this arrangement will be useful for front wheel drive applications.
For rear-wheel drive applications, it is contemplated that the
second end portion of output shaft 34 be coupled to an appropriate
driveline. One skilled in the art will appreciate that these
arrangements are merely exemplary and that one or both ends of
output shaft 34 may be utilized to provide output torque to
drivelines of a vehicle without departing from the scope of the
present disclosure.
[0024] Shift control system 35 includes a plurality of
electrically-actuated synchronizers which are operable for
selectively coupling a selected speed gear to first countershaft
26, second countershaft 30 or third countershaft 32 for
establishing the six forward and one reverse speed ratio drive
connections. These electrically-actuated synchronizers include a
first synchronizer 180 operable for selectively coupling/releasing
first and third speed gear 74 and fifth speed gear 98 to/from first
countershaft 26. A second synchronizer 182 is operable for
selectively coupling/releasing second speed gear 80 and fourth
speed gear 92 to/from second countershaft 30. A third synchronizer
184 is operable for selectively coupling/releasing sixth speed gear
104 to/from second countershaft 30. A fourth synchronizer 186 is
operable for selectively coupling/releasing headset speed gear 118
to/from third countershaft 32. Each synchronizer includes a sliding
sleeve (denoted by the suffix "A") which is splined for rotation
with and axial movement on a clutch hub (denoted by the suffix "B")
which, in turn, is fixed to one of first countershaft 26, second
countershaft 30 or third countershaft 32. A cone clutch assembly
(denoted by suffix "C") is positioned between the sliding sleeve
and an adjacent speed gear. As the synchronizer is engaged, the
cone clutch assembly causes the rotational speed of the hub to
match the speed gear. Once speed synchronization is complete, the
sliding sleeve is allowed to engage the adjacent speed gear.
[0025] Each synchronizer may be electrically powered to control
axial movement of the shift sleeves. It is to be understood that
any other type of power-operated device capable of moving each
sliding sleeve between its uncoupled and coupled positions is
within the scope of this disclosure.
[0026] Shift control system 35 also includes a first bi-directional
clutch 190 selectively operable to restrict rotation of sixth drive
gear 102 by interconnecting it with housing 152. A second
bi-directional clutch 192 is operatively coupled to fifth drive
gear 96. Second bi-directional clutch 192 may be selectively
operated to restrict fifth drive gear 96 from rotation by coupling
it to housing 152. Each of the bi-directional clutches is operable
to selectively allow or restrict rotation in either direction.
[0027] As shown in FIG. 3, shift control system 35 further includes
a motor/generator 200 that may be selectively connected to third
countershaft 32, a battery 202, a controller 204 and vehicle
sensors 206. Motor/generator 200 includes a fixed stator 208 and a
rotor 210 that is rotatably supported on third countershaft 32. A
fifth synchronizer 211 is operable for selectively
coupling/releasing rotor 210 to/from third countershaft 32.
Controller 204 receives various sensor input signals from sensors
206. Controller 204 is an electronically-controlled unit capable of
receiving data from the vehicle sensors and generating output
signals in response to the sensor input signals. The input signals
delivered to controller 204 can include, without limitation, engine
speed, throttle position, brake status, input shaft speed, tubular
shaft speeds, countershaft speeds, and output shaft speed.
Controller 204 is operable to coordinate and monitor actuation of
all the electrically-controlled devices associated with shift
control system 35, so as to permit power shifted sequential gear
changes automatically without any input from the vehicle operator.
As such, transmission 10 is capable of being smoothly shifted
automatically without power interruption.
[0028] Controller 204 also functions to control shifting of
motor/generator 200 between a "drive" mode, a "regeneration" mode
and a "no-load" mode. In the drive mode, the motor/generator 200
functions as an electric motor that is driven by electric power. In
the regeneration mode, motor/generator 200 functions as an electric
generator operable to perform regenerative braking where brake
torque provided by the motor/generator generates electricity that
is stored in battery 202. In the no-load mode, rotor 210 of
motor/generator 200 is permitted to rotate freely.
[0029] If desired, a manually-operable mode selector switch 212 can
be provided to shift transmission 10 from its automatic shift mode
to a manual shift mode. Mode switch 212 would, when actuated, allow
the vehicle operator to shift the gear shift lever manually to
effect sequential gear shifts without the use of a clutch pedal.
However, controller 204 would only permit the selective gear shift
to be completed if the current vehicle characteristics (i.e.,
engine speed, vehicle speed, etc.) permit completion of the
requested shift.
[0030] To operate the vehicle, engine 12 is started with the gear
shift lever in its PARK position. Each of first clutch 14 and
second clutch 16 are in the normally engaged state with their
respective drive connections completed. However, each of the
electrically-actuated synchronizers are released with each shift
sleeve located in its neutral uncoupled position such that no drive
torque is delivered to second countershaft 30. When the vehicle
operator moves the gear shift lever from the PARK position to the
DRIVE position, first actuator 42 is operated to place first clutch
14 in the open state. Second actuator 60 is operated to place
second clutch 16 in the open state. First synchronizer 180 is
actuated to drivingly interconnect first and third speed gear 74
and first countershaft 26. Second synchronizer 182 is controlled to
drivingly interconnect second speed gear 80 and second countershaft
30. First bi-directional clutch 190 is actuated to restrict
rotation of sixth drive gear 102. At this time, rotation of second
countershaft 30 and carrier 124 of planetary gearset 33 is
restricted. First actuator 42 is controlled to allow normally
closed first clutch 14 to transfer torque from input shaft 20
through first clutch 14, first transfer shaft 22, first and third
drive gear 72, first and third speed gear 74, first countershaft
26, second sun gear 127, planetary gearset 33 to output shaft 34 so
as to establish the first forward speed ratio drive connection
between the input shaft 20 and the output shaft 34. First clutch 14
is gradually engaged to smoothly accelerate the vehicle.
[0031] Thereafter, when the vehicle operating parameters indicate a
need to shift into the second forward gear ratio, controller 204
outputs signals to place first bi-directional clutch 190 in an open
condition and second bi-directional clutch 192 in a condition to
restrict rotation of fifth drive gear 96 and second sun gear 127.
Second synchronizer 182 remains energized to maintain a driving
interconnection with second speed gear 80 and second countershaft
30. Controller 204 coordinates the release of first clutch 14 and
the engagement of second clutch 16. As such, torque is transferred
from input shaft 20, through second clutch 16, second transfer
shaft 28, second drive gear 78, second speed gear 80, second
countershaft 30, carrier 124, and planetary gearset 33 to output
shaft 34 so as to establish the second forward speed ratio drive
connection.
[0032] To automatically establish the third forward gear ratio,
second bi-directional clutch 192 is placed in an open or
free-wheeling condition. Controller 204 signals first actuator 42
to cause inner clutch plates 36 to become engaged with outer clutch
plates 38 such that torque is transferred between input shaft 20
and first transfer shaft 22. Accordingly, both first clutch 14 and
second clutch 16 simultaneously transfer torque. It should be
appreciated that a 2-3 power shift occurs as controller 204
controls first clutch 14 to become engaged. During third forward
gear operation, both second sun gear 127 and carrier 124 are being
driven.
[0033] Once first clutch 14 and second clutch 16 are fully engaged
to establish the third forward gear ratio, fourth synchronizer 186
is actuated to drivingly interconnect headset speed gear 118 and
third countershaft 32. Headset drive gear 116 and headset speed
gear 118 define a ratio such that the rotational speed of headset
speed gear 118 is equal to the rotational speed of third
countershaft 32 while transmission 10 operates in the third forward
gear ratio. Accordingly, it should be appreciated that fourth
synchronizer 186 may simply be a dog clutch if a simple device is
desired. Once headset speed gear 118 and third countershaft 32 are
drivingly interconnected, second clutch 16 may be released. The
remaining 3-4, 4-5 and 5-6 up-shifts may occur as clutch-to-clutch
shifts while the driving interconnection between headset speed gear
118 and third countershaft 32 is maintained.
[0034] In particular, a 3-4 up-shift is accomplished by placing
second clutch 16 in the open condition and actuating second
synchronizer 182 to drivingly interconnect fourth speed gear 92 and
second countershaft 30. A 3-4 power shift is completed by gradually
disengaging first clutch 14 while second clutch 16 is gradually
engaged. To prepare for a 4-5 shift, first synchronizer 180 is
controlled to drivingly interconnect fifth speed gear 98 and first
countershaft 26. Once controller 204 determines that a 4-5 shift
should occur, second clutch 16 is gradually disengaged while first
clutch 14 is gradually engaged. In the fifth forward speed ratio,
power is transferred from input shaft 20 through first clutch 14,
first transfer shaft 22, fifth drive gear 96, fifth speed gear 98,
first countershaft 26, second sun gear 127, planetary gearset 33 to
output shaft 34. Simultaneously, power is transferred from input
shaft 20 through headset drive gear 116, headset speed gear 118,
third countershaft 32, first sun gear 120, planetary gearset 33 to
output shaft 34.
[0035] To accomplish a 5-6 up-shift, third synchronizer 184 is
actuated to drivingly interconnect sixth speed gear 104 and second
countershaft 30. First clutch 14 is gradually disengaged while
second clutch 16 is gradually engaged to complete the
clutch-to-clutch 5-6 shift.
[0036] The previous operational description relates to power being
provided solely by engine 12. Other modes of operation including
drive torque being supplied from electric motor/generator 200 in
the drive mode are also contemplated. Specifically, the vehicle may
be launched from a standstill without assistance from engine 12 if
battery 202 is sufficiently charged. Transmission 10 may transfer
torque output from electric motor/generator 200 while engine 12 is
turned off by controlling fourth synchronizer 186 to drivingly
couple rotor 210 to third countershaft 32. To produce the first
forward gear ratio in the electric drive mode, second
bi-directional clutch 192 is actuated to restrict fifth drive gear
96 from rotation. Additionally, first synchronizer 180 is actuated
to drivingly couple fifth speed gear 98 to first countershaft 26,
thereby restricting rotation of second sun gear 127. In similar
fashion, a first reverse gear ratio is provided by positioning the
components as previously described in relation to the electric
motor first forward gear ratio but by rotating rotor 210 in the
opposite direction.
[0037] To provide a maximum power output through transmission 10,
engine 12 may be operated simultaneously with electric
motor/generator 200. Motor/generator 200 is also operable in the
regeneration mode. In this mode of operation, energy is provided
from engine 12 or the kinetic energy of the moving vehicle. To
charge battery 202, fifth synchronizer 211 is actuated to drivingly
interconnect third countershaft 32 with rotor 210 such that rotor
210 is driven relative to stator 208 to generate electricity.
[0038] From the following description, it should be apparent that
transmission 10 provides an energy efficient assembly where
sequential shifts may be pre-selected thereby requiring only
clutch-to-clutch switching to effect a shift. Benefits include
smoother, quicker sequential shifts. The electric motor/generator
creates hybrid geartrain capability while maintaining a direct
mechanical torque path for non-hybrid operation. Engine off,
electric motor vehicle launch is also available. Depending on the
number of forward and reverse gear ratios desired, various
combinations of clutches and gearsets may be configured even though
not explicitly depicted in the drawings. Furthermore, the spaced
apart positioning of the first and second clutches assists in
cooling the clutches.
[0039] These and other variations disclose and describe merely
exemplary embodiments of the present invention. One skilled in the
art will readily recognize from such discussion, and from the
accompanying drawings and claims, that various changes,
modifications and variations may be made therein without department
from the spirit and scope of the invention as defined in the
following claims.
* * * * *